Thin wall product display tube

ABSTRACT

A thin-walled polypropylene product display tube. The thin-walled polypropylene product display tube includes a tubular member having a closed end, an open end, an inner diameter and, between the closed end and the open end, a first outer diameter, the open end terminating in a flared portion having a second outer diameter, the tubular member having a wall thickness sufficient to yield a level of haze equal to or less than 8%. A process for forming a thin-walled polypropylene product display tube is also provided.

RELATED APPLICATION

This application claims priority to U.S. Provisional Application No.61/920,986, filed on Dec. 26, 2013, the contents of which are herebyincorporated by reference in their entirety.

FIELD

Disclosed herein is a tobacco product display tube with improvedclarity.

ENVIRONMENT

Cigars have been sold by others individually in glass tubes which may besealed with stoppers. The tubes tend to somewhat resemble test tubesused for chemical samples. Such clear tubing permits the purchaser atthe point-of-sale to view the contents and select the cigar which ismost appealing.

It is desirable to replace glass with a material more suited for thepackaging of tobacco products, such as polypropylene (PP). Howeverheretofore, tubes constructed of PP tended to be hazy and milky inappearance, and unacceptable to a discerning, adult, tobacco consumer.

It would be advantageous if a polypropylene tobacco display tube couldbe developed which had enhanced clarity and appearance.

SUMMARY

In one aspect, a thin-walled polypropylene product display tube isprovided. The thin-walled polypropylene product display tube includes atubular member having a closed end, an open end, an inner diameter and,between the closed end and the open end, a first outer diameter, theopen end terminating in a flared portion having a second outer diameter,the tubular member having a wall thickness sufficient to yield a levelof haze equal to or less than 8%, as measured by ASTM D1003.

In one form, the inner diameter is substantially constant from a pointwhere the closed end expands to the inner diameter to the open end ofthe tubular member.

In another form, the first outer diameter is substantially constant froma point where the closed end expands to the first outer diameter to apoint where the flared portion begins.

In yet another form, the second outer diameter is selected to correspondto an outer diameter of a closure cap for the tubular member.

In still yet another form, the thin-walled polypropylene product displayfurther includes a closure cap fitted to the open end, the second outerdiameter of the flared portion of the tubular member mating with anouter diameter of the closure cap to form a smooth transition betweenthe tubular member and the cap.

In a further form, the closure cap comprises a plug member for engagingagainst an inner surface of the open end of the tubular member andsubstantially forming a seal.

In a yet further form, the product is a tobacco product and the sealformed by the engagement of the plug member against the inner surface ofthe open end of the tubular member is sufficient to maintain productshelf life for a period of at least one year.

In a still yet further form, the tubular member has a wall thickness ofless than about 0.061 inch.

In one form, the tubular member has a wall thickness of less than about0.050 inch.

In another form, the tubular member has a wall thickness of less thanabout 0.030 inch.

In yet another form, the tubular member is formed from a materialcomprising polypropylene random copolymer, polypropylene-ethylene impactcopolymer, polypropylene homopolymer, polypropylene copolymer and blendsthereof.

In still yet another form, the tubular member is formed from a materialcomprising polypropylene random copolymer.

In another aspect, a process for forming a thin-walled polypropyleneproduct display tube is provided. The process includes the step offorming a tubular member having a closed end, an open end, an innerdiameter and, between the closed end and the open end, a first outerdiameter, the open end terminating in a flared portion having a secondouter diameter, wherein the forming step yields tubular member having awall thickness sufficient to yield a level of haze equal to or less than8%, as measured by ASTM D1003.

BRIEF DESCRIPTION OF THE DRAWINGS

The forms disclosed herein are illustrated by way of example, and not byway of limitation, in the figures of the accompanying drawings and inwhich like reference numerals refer to similar elements.

FIG. 1 is a plan view of a typical point-of-sale cigar display.

FIG. 2 is a cross-sectional view of a cigar display tube/closure capcombination, configured with a thin-walled tube.

FIG. 3A is a cross-sectional view of the inventive cigar display tube,and

FIG. 3B is a larger, detail view of the open end of the cigar displaytube of FIG. 3A.

FIG. 4 is a cross-sectional view of the inventive cigar displaytube/closure cap combination.

DETAILED DESCRIPTION

Various aspects will now be described with reference to specific formsselected for purposes of illustration. It will be appreciated that thespirit and scope of the apparatus, system and methods disclosed hereinare not limited to the selected forms. Moreover, it is to be noted thatthe figures provided herein are not drawn to any particular proportionor scale, and that many variations can be made to the illustrated forms.Reference is now made to FIGS. 1-4, wherein like numerals are used todesignate like elements throughout.

Each of the following terms written in singular grammatical form: “a,”“an,” and “the,” as used herein, may also refer to, and encompass, aplurality of the stated entity or object, unless otherwise specificallydefined or stated herein, or, unless the context clearly dictatesotherwise. For example, the phrases “a device,” “an assembly,” “amechanism,” “a component,” and “an element,” as used herein, may alsorefer to, and encompass, a plurality of devices, a plurality ofassemblies, a plurality of mechanisms, a plurality of components, and aplurality of elements, respectively.

Each of the following terms: “includes,” “including,” “has,” “having,”“comprises,” and “comprising,” and, their linguistic or grammaticalvariants, derivatives, and/or conjugates, as used herein, means“including, but not limited to.”

Throughout the illustrative description, the examples, and the appendedclaims, a numerical value of a parameter, feature, object, or dimension,may be stated or described in terms of a numerical range format. It isto be fully understood that the stated numerical range format isprovided for illustrating implementation of the forms disclosed herein,and is not to be understood or construed as inflexibly limiting thescope of the forms disclosed herein.

Moreover, for stating or describing a numerical range, the phrase “in arange of between about a first numerical value and about a secondnumerical value,” is considered equivalent to, and means the same as,the phrase “in a range of from about a first numerical value to about asecond numerical value,” and, thus, the two equivalently meaning phrasesmay be used interchangeably.

It is to be understood that the various forms disclosed herein are notlimited in their application to the details of the order or sequence,and number, of steps or procedures, and sub-steps or sub-procedures, ofoperation or implementation of forms of the method or to the details oftype, composition, construction, arrangement, order and number of thesystem, system sub-units, devices, assemblies, sub-assemblies,mechanisms, structures, components, elements, and configurations, and,peripheral equipment, utilities, accessories, and materials of forms ofthe system, set forth in the following illustrative description,accompanying drawings, and examples, unless otherwise specificallystated herein. The apparatus, systems and methods disclosed herein canbe practiced or implemented according to various other alternative formsand in various other alternative ways.

It is also to be understood that all technical and scientific words,terms, and/or phrases, used herein throughout the present disclosurehave either the identical or similar meaning as commonly understood byone of ordinary skill in the art, unless otherwise specifically definedor stated herein. Phraseology, terminology, and, notation, employedherein throughout the present disclosure are for the purpose ofdescription and should not be regarded as limiting.

Provided is a product display apparatus, in particular a thin-walled,polypropylene tube for display of tobacco products, comprising a tubularmember having a closed end, an open end, an inner diameter and, betweenthe closed end and the open end, a first outer diameter, the open endterminating in a flared portion having a second outer diameter, thetubular member having a wall thickness sufficient to yield a level ofhaze equal to or less than 8%, as measured by ASTM D1003.

Resistance to moisture permeation is important in maintaining thequality of tobacco products. The moisture content of a cigar is animportant factor in determining how well the cigar will smoke andrealize its potential. It is well known that cigars stored in an aridenvironment become dry and hard and are undesirable to smoke. Dry cigarsburn too rapidly and taste hot and unpleasant, and are often describedas dusty and acrid. Once dry, a cigar looses most of its bouquet andcannot compare to a well-kept cigar. Conversely, a cigar smoked when toowet will not burn well and will require frequent relighting. Also,overly moist cigars taste sharp and aggressive. Therefore, for theoptimum smoking experience, cigars should be kept at some intermediateideal condition. The ideal conditions in which to keep cigars are 65 to70 percent relative humidity and 61 to 64 degrees Fahrenheit, the mostimportant being the relative humidity. Fine cigars are made of delicatehigh quality natural leaf tobacco possessing a smooth and rich flavorand should be consumed within these ideal conditions to realize thefullest enjoyment.

Cigar humidors are well known in the prior art and many cigar smokersown a tabletop model. The typical prior art humidor is a wooden box witha hinged top containing a source of moisture which is allowed toevaporate. The evaporating moisture is absorbed by the air within thehumidor which in turn is absorbed by the dry cigars contained therein.The moisture source within these types of humidors can bewater-absorbent stones, sponges, or plastic storage vessels. Thistechnique of humidification is adequate for bulk cigars placed withinthe humidor, but is problematic for cigars sold individually withinprepackaged tubes or containers because the moisture will be unable topenetrate the prepackaged container seal.

More recently, it has been found that packaging individual cigars in amoisture permeation resistant polypropylene tube permits not only apleasing visual display of the cigar at a point-of-sale location, butalso maintains the proper humidity within the display tube for periodsin excess of about one year. In arid environments, adequate moisture isretained within the tube, while in a humid environment; excess moistureis excluded from the tube.

Many natural and synthetic polymers can be attacked by ultra-violetradiation and products made using these materials may crack ordisintegrate, if they're not UV-stable. Over time polypropylene candiscolor, becoming hazy, inhibiting the transparency or clarity. Theproblem is known as UV degradation, and is a common problem in productsexposed to sunlight. The ultra-violet rays activate the tertiary carbonbonds to form free radicals, which then react further with oxygen in theatmosphere, producing carbonyl groups in the main chain. The exposedsurfaces of such products may then discolor and crack. While notaffecting tobacco product quality contained within the tube, suchdiscoloration can negatively affect the prospective purchaser'sperception of product freshness and even quality.

It has been found that a polypropylene cigar display tube can be madehaving thin walls such that a display tube will have a high degree ofclarity and retain its clarity over time. Moreover, due to an effectiveseal, the product can retain its freshness, for a period in excess of atleast about one year. Thus, in one form, a thin-walled polypropylene(tobacco) product display tube is provided. While cigars are discussedin connection with the display tubes disclosed herein, anysimilarly-sized product could be stored and displayed in such apoint-of-sale tube display.

Point-of-sale product displays may be made of stiff paperboard orcardboard, and may have an array of die cut holes on at least onesubstantially horizontal surface for vertically holding the tobaccodisplay tubes. The most advantageous and visually pleasing manner ofdisplaying the cigars in the tubes is to place the tubes cap-end downwithin the product display, such that the clear, closed end of thedisplay tube, and therefore the cigar within, is visually accessible tothe prospective purchaser. Upon selection of a product by the purchaser,the tube is withdrawn from the product display vertically.

In one form, a thin-walled tube and an effective commercially availableclosure cap are employed. In the aforementioned point-of-sale productdisplays, any difference between the outer diameter (O.D.) of the tubeand that of the cap resulting in a small ledge may impede the withdrawalof the tube from the cardboard display. During withdrawal of a cigar,the ledge may catch (snag) an edge of the die cut hole in the displaybox and frustrate the smooth withdrawal of the cigar. In some instances,the snag may possibly upset the entire display.

In order to remedy this difficulty, a product display tube comprising athin-walled, cylindrical polypropylene tube having a closed end, an openend and inner and outer diameters between the ends, the open endterminating with a flared outer circumference is provided.Advantageously, the outer diameter at the flared outer circumference ispredetermined to correspond and mate to the outer diameter of a closurecap for the tube. In this way, a smooth transition is provided betweenthe outer surfaces of the thinner-walled cigar tube and the end cap,such that no ledge is created between the two, and the cigar tube can bewithdrawn smoothly and evenly from a point-of-sale product display.

As shown in FIG. 1, a tobacco product display apparatus 110, such as fordisplay of cigars at a point-of-sale location, is provided. A cardboardpoint-of-sale display box 100 has an array of die cut holes 102 forholding and displaying tobacco products within display tubes 110. Theapparatus of FIGS. 3A and 3B takes the form of a thin-walled cylindricalpolypropylene tube 110, which includes a tubular member 118, having arounded, closed end 112 and an open end 113, similar in form to a testtube. A tobacco product, such as a cigar (not shown), is placed into thedisplay tube 110 through the open end 113, and a closure cap 111 isplaced into the open end 113 so as to seal the cigar within the displaytube 110 against both the ingress and egress of moisture.

As best seen in FIG. 2, closure cap 111 includes a plug section 114,designed to penetrate a short distance into open end 113 of display tube110. Plug section 114 has at least one moisture sealing ring 116 formedaround its circumference, such that the at least one moisture sealingring 116 is forced into circumferential contact with the inner diameter(I.D.) of the display tube 110.

Advantageously, display tube 110 is made of polypropylene, a moisturepermeation resistant polymer that is easily and inexpensively moldedinto the appropriate size and shape, as well as being resistant tomoisture penetration, both into and out of the tube, once sealed.

It has been found that polypropylene tubes used for tobacco productcontainment can be optimized for clarity by reducing the wall thicknessof the tubing without compromising the long term moisture permeationresistance of the tubing. Advantageously, the thin-walled polypropyleneproduct tubes disclosed herein demonstrate long term clarity, such asretaining a level of haze equal to or less than 8%, as measured by ASTMD1003, for periods exceeding one year.

Cigar display tubes may have wall thicknesses in excess of about 0.120″.The tubing outer diameter may match that of the closure caps, which isabout 0.689″. However, as seen in FIG. 2, when the wall thickness of thedisplay tube 110 is reduced, a problem may occur. That problem relatesto the fact that a ledge 115 may be created between the contact pointsof the closure cap 111 and the open end of the display tube 110.

As shown in FIGS. 3A and 3B, in order to eliminate this problem, theinner diameter of the display tube 110 is keep substantially constantfrom a point where the closed end 112 expands to the inner diameter tothe open end 113 of the display tube 110, and the outer diameter (O.D.)is constant from a point where the closed end 112 expands to said outerdiameter to a point where the flared outer circumference 120 begins.

FIG. 4 illustrates how the flared outer circumference 120, at itsgreatest circumference, matches (essentially equals) the outercircumference of the closure cap 111, so as to form a smooth transitionbetween display tube 110 and closure cap 111.

The overall wall thickness of the polypropylene tube between the endscan be limited to less than about 0.061″, or even less than about0.050″, or even less than about 0.030″, which results in improved tubeclarity and product visibility for the purchaser. Even with thesethinner wall diameters it has been observed that the shelf life of thetobacco product contained in the tube is in excess of about 12 months.

In one form, tubular member 118 is formed from a polypropylene materialcomprising polypropylene random copolymer, polypropylene-ethylene impactcopolymer, polypropylene homopolymer, polypropylene copolymer and blendsthereof. In another form, tubular member 118 is formed from a materialcomprising polypropylene random copolymer. In another form, tubularmember 118 is injection molded from a high clarity polypropylenecopolymer. One suitable material is Metocene RM2231 resin, availablefrom LyondellBasell Industries, of Houston, Tex. Another is BorclearRB709CF, a random copolymer polypropylene available from Borealis Inc.of Port Murray, N.J.

In another aspect, a process for forming a thin-walled polypropyleneproduct display tube is provided. The process includes the step offorming a tubular member having a closed end, an open end, an innerdiameter and, between the closed end and the open end, a first outerdiameter, the open end terminating in a flared portion having a secondouter diameter, wherein the forming step yields tubular member having awall thickness sufficient to yield a level of haze equal to or less than8%, as measured by ASTM D1003.

Illustrative, non-exclusive examples of systems and methods according tothe present disclosure have been presented. It is within the scope ofthe present disclosure that an individual step of a method recitedherein, including in the following enumerated paragraphs, mayadditionally or alternatively be referred to as a “step for” performingthe recited action.

INDUSTRIAL APPLICABILITY

The assemblies and processes disclosed herein are applicable to thetobacco industry, in particular that portion directed to products forsmoking enjoyment.

Although many of the teachings herein are addressed to the packaging anddisplay of cigars, the teachings are equally applicable to any otherforms of tobacco product, including cigarettes, cigarillos, pipes,e-vapor products and other smoking articles in any form or shape, all ofwhich are contemplated herein with reference to a “tobacco product.”

While the present invention has been described and illustrated byreference to particular forms, those of ordinary skill in the art willappreciate that the invention lends itself to variations not necessarilyillustrated herein. For this reason, then, reference should be madesolely to the appended claims for purposes of determining the true scopeof the present invention.

We claim:
 1. A thin-walled polypropylene product display tube comprisinga tubular member having a closed end, an open end, an inner diameterand, between the closed end and the open end, a first outer diameter,the open end terminating in a flared portion having a second outerdiameter at a greatest circumference thereof, the tubular member havinga wall thickness sufficient to yield a level of haze equal to or lessthan 8%, as measured by ASTM D1003, and a closure cap fitted to the openend, the greatest circumference of the flared portion mating with anoutermost circumference of the closure cap to form a smooth transitionwith no ledge between the greatest circumference of the flared portionand the outermost circumference of the closure cap.
 2. The thin-walledpolypropylene product display tube of claim 1, wherein the innerdiameter is substantially constant from a point where the closed endexpands to the inner diameter to the open end of the tubular member. 3.The thin-walled polypropylene product display tube of claim 1, whereinthe first outer diameter is substantially constant from a point wherethe closed end expands to the first outer diameter to a point where theflared portion begins.
 4. The thin-walled polypropylene product displaytube of claim 1, wherein the closure cap comprises a plug member forengaging against an inner surface of the open end of the tubular memberand substantially forming a seal.
 5. The thin-walled polypropyleneproduct display tube of claim 4, wherein the product is a tobaccoproduct and the seal formed by the engagement of the plug member againstthe inner surface of the open end of the tubular member is sufficient tomaintain product shelf life for a period of at least one year.
 6. Thethin-walled polypropylene product display tube of claim 1, wherein thetubular member has a wall thickness of less than about 0.061 inch. 7.The thin-walled polypropylene product display tube of claim 6, whereinthe tubular member has a wall thickness of less than about 0.050 inch.8. The thin-walled polypropylene product display tube of claim 7,wherein the tubular member has a wall thickness of less than about 0.030inch.
 9. The thin-walled polypropylene product display tube of claim 1,wherein the tubular member is formed from a material comprisingpolypropylene random copolymer, polypropylene-ethylene impact copolymer,polypropylene homopolymer, polypropylene copolymer and blends thereof.10. The thin-walled polypropylene product display tube of claim 9,wherein the tubular member is formed from a material comprisingpolypropylene random copolymer.
 11. A process for forming a thin-walledpolypropylene product display tube, the process comprising forming atubular member having a closed end, an open end, an inner diameter and,between the closed end and the open end, a first outer diameter, theopen end terminating in a flared portion having a second outer diameterat a greatest circumference thereof, wherein the forming step yields thetubular member having a wall thickness sufficient to yield a level ofhaze equal to or less than 8%, as measured by ASTM D1003, and providinga closure cap fitted to the open end, the greatest circumference of theflared portion mating with an outermost circumference of the closure capto form a smooth transition with no ledge between the greatestcircumference of the flared portion and the outermost circumference ofthe closure cap.
 12. The process of claim 11, wherein the inner diameteris substantially constant from a point where the closed top end expandsto the inner diameter to the open end of the tubular member.
 13. Theprocess of claim 11, wherein the first outer diameter is substantiallyconstant from a point where the closed end expands to the first outerdiameter to a point where the flared portion begins.
 14. The process ofclaim 11, wherein the closure cap includes a plug member for engagingagainst an inner surface of the open end of the tubular member andsubstantially forming a seal.
 15. The process of claim 14, wherein theproduct is a tobacco product and the seal formed by the engagement ofthe plug member against the inner surface of the open end of the tubularmember is sufficient to maintain product shelf life for a period of atleast one year.
 16. The process of claim 11, wherein the tubular memberhas a wall thickness of less than about 0.061 inch.
 17. The process ofclaim 16, wherein the tubular member has a wall thickness of less thanabout 0.050 inch.
 18. The process of claim 17, wherein the tubularmember has a wall thickness of less than about 0.030 inch.
 19. Theprocess of claim 11, wherein the tubular member is formed from amaterial comprising polypropylene random copolymer,polypropylene-ethylene impact copolymer, polypropylene homopolymer,polypropylene copolymer and blends thereof.
 20. The process of claim 19,wherein the tubular member is formed from a material comprisingpolypropylene random copolymer.
 21. A thin-walled polypropylene productdisplay tube comprising a tubular member having a closed end, an openend, an inner diameter and, between the closed end and the open end, afirst outer diameter, the open end terminating in a flared portionhaving a second outer diameter and a greatest circumference, the tubularmember having a wall thickness sufficient to yield a level of haze equalto or less than 8%, as measured by ASTM D1003, and wherein the greatestcircumference of the flared portion is selected to correspond to anoutermost circumference of a closure cap for the tubular member suchthat no ledge exists between the tubular member and the closure cap.